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DIEDRICH MANUFACTURING, INC. IR-5 Operator And Maintenance Manual

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DIEDRICH MANUFACTURING, INC.
Operator and Maintenance Manual
Keep this manual with the afterburner at all times and
Technical Support: support@diedrichroasters.com
PROPRIETARY RIGHTS NOTICE: All rights reserved. No part of this material may be reproduced or transmitted
in any form or by means, electronic, mechanical or otherwise, including photocopy and recording or in connection
with any information storage or retrieval system, without the written
IR-5 and IR-12
READ THIS MANUAL
For important safety, installation, operation and
maintenance instructions.
locate it in a prominent place.
Issued: 3-14-2013
DIEDRICH MANUFACTURING, INC.
P.O. Box 430
Ponderay, Idaho 83852
Telephone: (208) 263-1276
Toll Free: (877) 263-1276
Fax: (208) 265-4584
Copyright 2013 © by Diedrich Manufacturing, Inc.
permission of Diedrich Manufacturing, Inc.

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Summary of Contents for DIEDRICH MANUFACTURING, INC. IR-5

  • Page 1 DIEDRICH MANUFACTURING, INC. IR-5 and IR-12 Operator and Maintenance Manual READ THIS MANUAL For important safety, installation, operation and maintenance instructions. Keep this manual with the afterburner at all times and locate it in a prominent place. Issued: 3-14-2013 DIEDRICH MANUFACTURING, INC.

  • Page 2: Table Of Contents

    DIEDRICH MANUFACTURING, INC. Contents IMPORTANT SAFEGUARDS ........................4 COMPONENT DESCRIPTION ........................5 INITIAL START-UP ............................9 SEASONING THE ROASTING DRUM ....................... 11 ROASTING FOR CONSUMPTION ......................12 SHUT DOWN ..............................16 ROASTING LOG ............................16 CLEANING ..............................19 GENERAL ..............................19 DAILY BASIS ...............................
  • Page 3 PREFACE The Diedrich IR-5 and IR-12 Coffee Roasters are identical in construction detail and features offered. They differ only in scale so the descriptions provided in this Manual are generic and if differences exist, they will be specifically mentioned. This manual covers all of the components which make up a coffee roaster.

  • Page 4: Important Safeguards

    IMPORTANT SAFEGUARDS Proper installation, cleaning and safe operation of the coffee roaster is the owner’s and operator’s responsibility. Read this manual carefully for important operation, maintenance and safety information. All persons operating the Diedrich Coffee Roaster must be familiar with this manual and properly trained in the safe and proper use of the roasting system.

  • Page 5: Component Description

    Never under ANY circumstances, while operating or servicing the machine, thrust a hand or arm into the roasting drum or any other access port until the roaster is switched “OFF” and disconnected at its electrical source. Keep clear of moving parts such as the drive chain at the rear of the roaster and the agitator arm and brushes in the cooling bin if so equipped.
  • Page 6 Figure 1 - Left and Front Views Page 6 Diedrich Manufacturing, Inc. www.diedrichroasters.com...
  • Page 7 Figure 2 - Roaster Right Side and Rear End Views Page 7 Diedrich Manufacturing, Inc. www.diedrichroasters.com...
  • Page 8 The operator control panel is described as follows. AIR light: This light may be on or off depending on the model of roaster. Standard model roasters have a red light. If it is illuminated there is an air flow restriction and the roaster will not ignite the burners. Universal model roasters have a blue air light.

  • Page 9: Initial Start-Up

    GAS switch: This switch turns on the gas. AGITATOR switch: This switch turns on the agitator in the cooling bin. GAS knob: This knob controls the flame level. The intensity can be viewed through the window below the below the sample trowel and gas pressure on the manometer on the top or the roaster.
  • Page 10 Standard model roasters and Universal model roasters have different start-up procedures. A Standard roaster has a red air light on the control panel a serial number that starts with “S”. A Universal roaster has a blue air light on the control panel and a serial number that starts with “U”.

  • Page 11: Seasoning The Roasting Drum

    SEASONING THE ROASTING DRUM The drum of the roaster must be seasoned before roasted coffee is fit for consumption. Use an inexpensive coffee for the seasoning process. Do not use a Robusta coffee as it does not emit enough oil for the seasoning process. The new drum requires from 5 to 10 seasoning roasts to become properly oiled.

  • Page 12: Roasting For Consumption

    turning to steam. At this stage in the roast, the air flowing through the roasting drum becomes a more uniform heat medium. The roast will progress from the yellow to the cinnamon color as the coffee begins to expel a fair volume of carbon dioxide (CO2) gas. After the cinnamon color stage of the roast is reached, the coffee will start its first cracking.
  • Page 13 Further information on roasting is available during the Diedrich Manufacturing Inc. roasting seminars. Follow the procedures outlined in the Start-Up section. Move flame control to “HIGH” (temperature) setting for warm-up. Watch through burner front view window for burner ignition. Preheat the empty drum until the digital unit reads 415º (213ºC) or until you reach your desired charge temperature.
  • Page 14 Diedrich Coffee Roaster utilizes the moisture that is present in the green coffee to assist in the conduction of heat to the core of the bean. Our philosophy is to allow the beans to absorb heat at their own natural potential since various types of coffee have different weight densities and absorb heat differently.
  • Page 15 is relatively easy for the air to pick the chaff up when the particles are large and light, but more difficult later in the roast. This chaff removal procedure is very important especially when working with coffee varietals that have very heavy chaff coatings. Decaffeinated coffee has no chaff on the exterior of the bean, so this procedure becomes unnecessary.

  • Page 16: Shut Down

    Note: If any of the following happens: Excessive smoke in the room. Smoke coming from the sample trowel port. Longer cool down times. Excessive chaff in the burner compartment. Check for the following: Excessive build-up of residue throughout the airflow system within the roaster. Excessive build-up of residue in the exhaust ducting.
  • Page 17 Make entries into the log between roasts or after the green beans have been discharged into the roasting drum before the coffee roast requires all your attention. Type of Coffee: Naturals (unwashed coffees, i.e. Indonesians) have much more chaff than washed coffees (i.e. Central and South American coffees); and decafs have virtually no chaff on the outside of the bean.
  • Page 18 Table 1 - Roast Log Page 18 Diedrich Manufacturing, Inc. www.diedrichroasters.com...

  • Page 19: Cleaning

    NOTE: THE SERVICING OF THE ROASTER IS EXTREMELY IMPORTANT. THE ROASTING LOG WILL INDICATE ABOUT WHEN AND HOW OFTEN THE MACHINE NEEDS TO BE SERVICED. DO NOT TAKE THE SIGNIFICANCE OF THE LOG LIGHTLY! CLEANING GENERAL CAUTION: ALWAYS DISCONNECT ROASTER AT ELECTRICAL SOURCE (at circuit breaker or safety shut-off switch) BEFORE SERVICING MOTORS OR MOVING COMPONENTS.
  • Page 20 The types of coffees and degree of roast will also influence the amount of cleaning required. Some geographic regions, more than others, are known for their dark roasted coffees. With darker roasts, more oils come to the surface of the bean, which in turn contributes to more oil in the exhaust smoke.
  • Page 21 Diedrich Roaster Cleaning & Maintenance Schedule Daily Date √ when complete Initials Vacuum all chaff from the chaff collection compartment. Vacuum any chaff and/or bean debris from the infrared burner compartment. Vacuum any residual chaff from impeller compartment. Inspect perforated cooling bin screen for clogging. Clean as necessary with a screen roller, wire brush or by utilizing a sharp point to clean out the perforated holes.

  • Page 22: Daily Basis

    DAILY BASIS Spend time every day doing general cleaning inside and outside of the roaster and checking for residue build-up. After every four hours of roasting, remove the chaff from the lower compartments. To maintain sanitary standards and general appearance, clean and polish the outside surfaces of the roaster on a regular basis.
  • Page 23 Figure 4 - Roaster Compartments 1. Chaff Collection Compartment 2. Impeller Compartment 3. Cooling Bin 4. Infrared Burner Compartment 5. Roast Air Duct 6. Exhaust Ducting 7. Vacuum Tube Page 23 Diedrich Manufacturing, Inc. www.diedrichroasters.com...

  • Page 24: Lower Compartments

    LOWER COMPARTMENTS The chaff collection compartment’s function is to collect the chaff, (the parchment that separates from the coffee during the roasting process). Therefore, this area fills up fairly rapidly and requires constant emptying. Residue will slowly accumulate on the metal surfaces within the compartment.

  • Page 25: Cooling Bin

    access doors on each side of the roaster, above the control panel. Keep clean by vacuuming or sweeping chaff before it exceeds a depth of ½-inch (1.27 cm). Use care in cleaning around pilot gas lines and igniter leads. A bent gas line can hamper burner ignition.
  • Page 26 Clean perforated holes enhance good airflow and decreases roasted bean cooling times. For cooling efficiency and to prevent fire hazard, the area below the screen must be cleaned along with the lower compartments after every four hours of roasting. The area under the cooling bin is accessible from the chaff box door.

  • Page 27: Blower Impeller

    5. Before reassembling in reverse order, clean the agitator assembly. BLOWER IMPELLER The impeller compartment is a major collection point for residue build-up. The residue collects on the all the metal surfaces in this compartment, including the impeller itself. Please follow the instructions below for removing the impeller protective shroud and the impeller.
  • Page 28 An example of a very dirty impeller compartment. Roaster Impeller Removal Instructions: Disconnect power to the roaster. Unscrew the two (2) wing bolts securing the impeller shroud. (See Illustration #1) Once the wing bolts are unscrewed push the impeller shroud down. This should dislodge the impeller shroud from the mounting brackets. Slide the shroud to the right and pull the left side of the shroud out of the impeller compartment first.
  • Page 29 utilizing the screw driver. Turn the impeller ½ turn and repeat this procedure. Now, try to remove the impeller by hand as described above.  If the impeller is still lodged on the shaft you may have to use a gear puller to remove the impeller.
  • Page 30 Unscrew these two wing nuts ILLUSTRATION #1 Page 30 Diedrich Manufacturing, Inc. www.diedrichroasters.com...
  • Page 31 Push the shroud down. Slide it to the right and pullout the left side from the roaster first. Note: This should free the shroud, now set it aside. ILLUSTRATION #2 Page 31 Diedrich Manufacturing, Inc. www.diedrichroasters.com...
  • Page 32 Clean out set screw holes so you can firmly insert the Allen wrench Clean out set screw holes so you can firmly insert the Allen wrench ILLUSTRATION #3 Page 32 Diedrich Manufacturing, Inc. www.diedrichroasters.com...

  • Page 33: Vacuum Tube

    Insert Allen wrench and turn counter clockwise to loosen. Perform this same procedure on 2 set screw. ILLUSTRATION #4 VACUUM TUBE The vacuum tube is an aluminum tube that is connected to the vacuum sensor located below the burner compartment. The vacuum tube termination point is in the top of the impeller compartment.

  • Page 34: Roast Air Duct

    Use a small pointed object, like a paperclip, etc. to clean out any debris that may have accumulated in the vacuum tube opening. 8.10 ROAST AIR DUCT The roast air duct is the 4” diameter pipe located to the left of the drum chain when looking at the back of the roaster.

  • Page 35: Roaster Exhaust Ducting

    Remove this bolt and the one on the other side of the elbow. Take the elbow from the straight section and clean the inside of the pipes with a putty knife, wire brush, or use the special cleaning tool Diedrich manufactures for this task.
  • Page 36 A professional chimney sweep or company experienced in cleaning industrial or restaurant equipment that is subject to heavy tar and/or oily build-up must do the cleaning of the exhaust ducting. Make sure that the company is properly licensed and bonded. Improper cleaning can result in a fire. The vent ducting is an integrated part of the roasting system.

  • Page 37: Maintenance

    Even if residue build-ups do not exceed 1/8 inch (.3 cm) per year, clean system annually in order to prevent the accumulated residue from becoming baked-onto surfaces making it impossible to clean. Excessive build-up of residue will have an adverse effect on the airflow and the efficient performance of the roaster.

  • Page 38: Blower Motor

    BLOWER MOTOR Sealed motor. No service required. See Figure 7 Figure 5 - Blower Motor and Impeller Page 38 Diedrich Manufacturing, Inc. www.diedrichroasters.com...

  • Page 39: Agitator Motor

    AGITATOR MOTOR Sealed motor. No service required. See Figure 8 Figure 6 - Agitator Motor and Drive Shaft Page 39 Diedrich Manufacturing, Inc. www.diedrichroasters.com...

  • Page 40: Drum Motor

    DRUM MOTOR Sealed motor. No service required. See Figure 9 Figure 7 - Drum Motor Page 40 Diedrich Manufacturing, Inc. www.diedrichroasters.com...

  • Page 41: Roasting Drum Drive Chain

    ROASTING DRUM DRIVE CHAIN Remove electrical power and lock it out. Oil the chain every six months with SAE20 non-detergent or sewing machine oil. For access, remove rear cover panel. Do not over-lubricate. See Figure 2 WARNING - KEEP FINGERS, HAIR, AND LOOSE CLOTHING CLEAR OF MOVING CHAIN AND SPROCKETS.

  • Page 42: Front And Rear Drum Bearings

    on the motor until its weight draws the slack out of the chain. Use wrench to tighten the mounting bolts securely to prevent a loose engagement of chain and motor sprocket. When tightening bolts, be sure motor remains in a level, horizontal position. With a new machine the drum drive chain may need to be adjusted several times to compensate for the initial stretching of the chain.

  • Page 43: Burner & Drum Chaff Tray Access Doors

    WARNING: Keep fingers, hair and loose clothing clear of moving chain and sprockets. Remove electrical power and lock it out. Before lubricating the rear bearing STOP THE DRUM FROM ROTATING. To lubricate the front bearing attach grease gun to bearing fitting. Inject 1-2 pumps of grease into the bearing fitting.

  • Page 44: Agitator Assembly Adjustment

    Check drive shaft coupling setscrews every six months. The couplings are located in the under the cooling bin forward of the agitator motor. The drive shaft connects the motor to the agitator assembly in the cooling bin. Tighten the set screws on the agitator shaft couplings.

  • Page 45: Cooling Bin

    Lubricate the pivot mechanism. Put a little of the food grade grease used on the front/back bearings on your finger and generously apply here. 9.12 COOLING BIN To remove cooling bin assembly from Roaster frame: A. Lift agitator assembly straight up from gearbox drive shaft. There are no screws securing the agitator to the drive box.

  • Page 46: Fire Control - Read Carefully And Practice

    A. Tilt and lower cooling bin to seat it over the six screw holes in frame of roaster. It is helpful to use a pair of small pins (diameter of screws) to align holes in the screen and the holes in frame of roaster. B.
  • Page 47 4. Roasting Drum Fire. Warning! Do not discharge coffee into cooling bin. Exposure to oxygen can accelerate the fire. ____ Remove Sample Trowel and spray water into the sample trowel tube. ____ Remove the Aluminum funnel and push up on the Hopper Handle. Spray water into the hopper.
  • Page 48 ____ Discharge a liberal amount water or CO2 into the Chaff Collection Compartment. Repeat if required. ____ If the fire is out of control disconnect main power supply and call 911 or Fire Department and evacuate all personnel to a safe area away from fire and smoke. ____ Proceed to Step-10 when the fire is completely extinguished.
  • Page 49 Fx4L515 Gas Valve Control Module Honeywell S8610U Table 3 - Parts List Roaster Solaronics Model burner Gas type drill size gas pressure (in H2O) IR-5 #7X181 *2 USA natural 37000 IR-5 #7X181 *2 USA LPG 37000 IR-5 #7X181 *2 propane 11.5...

This manual is also suitable for:

Ir-12

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